Plank with veneer material fused to rigid core

Abstract

A plank has a first portion with at least three layers. The first layer is of a plant material, and has an inner surface that includes a nonwoven fabric or a fiberglass mesh. The second layer is of an adhesive paper material that includes a macromolecular glue where the macromolecular glue is 50-55% melamine, 35-40% plasticizer, and 3-5% formaldehyde. The third layer is one of bamboo, wood, or paper. The plank has a second portion, which may be of a plastic composite base material or a magnesium oxide composite base material. When the second portion is of a plastic composite material, the first portion is fused to the second portion by cold pressing or a polyurethane reactive adhesive. When the second material is of a magnesium oxide composite base material, the first portion is thermally pressed to the second portion by cold pressing, hot pressing or a polyurethane reactive adhesive.

What is claimed: 
     
       1. A plank comprising:
 a first portion comprising: 
 a first layer comprising a plant material, the first layer having an outer surface and an opposite inner surface, the inner surface including one of a nonwoven fabric and a fiberglass mesh; 
 a second layer comprising an adhesive paper material including a macromolecular glue, the macromolecular glue comprising 50-55% melamine, 35-40% plasticizer, and 3-5% formaldehyde; 
 a third layer comprising one of bamboo, wood, or paper; and 
 a second portion comprising a plastic composite base material; 
 wherein the first portion is fused to the plastic composite base material by one of cold pressing and a polyurethane reactive adhesive. 
 
     
     
       2. The plank of  claim 1 , wherein the plant material of the first layer of the first portion comprises bamboo and/or wood, and the first layer and the third layer of the first portion are constructed from bamboo and/or wood that has been dry balanced and permeated with flame retardant material. 
     
     
       3. The plank of  claim 1 , wherein the one of the bamboo, wood, or paper of the third layer of the first portion is plant material that has been de-sugared and skimmed. 
     
     
       4. The plank of  claim 3 , wherein the plant material of the third layer of the first portion that has been de-sugared and skimmed is de-sugared and skimmed at a controlled steam pressure between 245 and 490 kPa. 
     
     
       5. The plank of  claim 1 , wherein the plant material of the first layer of the first portion is a veneer with a thickness of at least 0.45 mm, the first layer includes the nonwoven fabric, and the nonwoven fabric is at least 20 mesh nonwoven fabric. 
     
     
       6. The plank of  claim 1 , wherein the adhesive paper material of the second layer of the first portion comprises 0.05 mm thick adhesive paper infused with the macromolecular glue. 
     
     
       7. The plank of  claim 1 , wherein the third layer is a paper, and the paper comprises 0.2 mm thick kraft paper. 
     
     
       8. The plank of  claim 1 , wherein the plastic composite base material is produced by extruding out a compound, the compound produced from a mixture including one or more of polyvinyl chloride powder, coarse whiting and light calcium compound powder, stabilizer, polyethylene wax, internal lubricant, plasticizer, and impact modifier. 
     
     
       9. The plank of  claim 1 , wherein the plastic composite base material has a first extruded substrate layer, a second extruded substrate layer and a third extruded substrate layer, the second extruded substrate layer being located between and in direct contact with the first and third extruded substrate layers, the second extruded substrate layer having different physical properties than the first and third extruded substrate layers, at least one of the first extruded substrate layer and third extruded substrate layer having higher hardness than the second extruded substrate layer. 
     
     
       10. The plank of  claim 9  wherein at least one of the first extruded substrate layer and third extruded substrate layer of the plastic composite base has higher resistance to impact than the second extruded substrate layer. 
     
     
       11. The plank of  claim 9  wherein the first and third extruded substrate layers have identical physical properties. 
     
     
       12. The plank of  claim 1  wherein the cold press occurs at a pressure of about 8 Kg/cm2 to about 10 Kg/cm2 and a time of between about 3 hours and about 5 hours. 
     
     
       13. The plank of  claim 1  further comprising a balancing layer applied to a base of the plastic composite base material, the balancing layer comprising one of a melamine impregnated paper layer and a vinyl layer.